Tradition on the way to the future – io accompanies the Klosterfrau Group in building a new syringe line

Highest cleanroom quality: Suspended LAF unit for flexible supply in syringe filling. (Copyright: io)

Automated unloading and packaging of blistered, autoclaved syringes in the cleanroom. (Copyright: io)

Safe and precise operation of the syringe filling in cleanroom class C – for the highest product quality. (Copyright: io)

Maximum safety: Individualization of injections with seamless quality control for the highest standards. (Copyright: io)

To meet the increasing demand from patients and customers, the renowned Klosterfrau Group decided to establish a new production line at the Berlin manufacturing site. io took on comprehensive master planning and execution support.

With traditional products, such as the now iconic Melissa spirit, the company Klosterfrau has developed into one of the most well-known manufacturers in self-medication over nearly 200 years. The Klosterfrau Group has always been influenced by a culture that continually combines tradition and modernity. At the group's largest production site in Berlin, in addition to distillates, nasal sprays, juices, and drops, pre-filled syringes for diagnostic and therapeutic applications are produced.

Klosterfrau strengthens the pharmaceutical location Germany with strategic investment

Sustainable production and innovations in new technologies are topics that drive the employees at Klosterfrau Berlin. To secure existing jobs and create new ones, the Klosterfrau Group decided to invest heavily as early as 2021.

The start of the multi-year investments was a production line for manufacturing gels in plastic syringes on a building level. The system includes filling the gels into syringes in the cGMP cleanroom class C under laminar flow, as well as labeling the syringes, piston rod assembly, blistering, terminal sterilization, and final packaging in the cGMP cleanroom class D.

io impresses with comprehensive know-how and project experience

Klosterfrau Berlin GmbH entrusted io with responsibility for master planning and execution support.

During the planning phase, a comprehensive needs analysis was conducted, followed by the development of a concept. Additionally, io was responsible for ensuring compliance with all necessary permits in accordance with applicable legal regulations and standards.

The design and implementation planning included detailed planning, including layout, selection of technical components, and planning for integration into the existing infrastructure. After completing the planning basis, io also handled the tendering and awarding of all required trades.

In the realization phase, io accompanied the project through complete construction supervision and quality control until the plant was completed. Extensive testing runs were subsequently carried out as part of qualification to ensure functionality, performance, and compliance with the required quality standards.

io delivers efficient and future-proof production even under challenging conditions

As a result, the new production line is designed for filling quantities from 300 to 750 kg and can produce between 15,000 and 150,000 syringes per batch, depending on the product. The new line supports versatile production and allows filling in more than 20 different formats. On a single floor, syringes are filled, packaged, and autoclaved year-round in a 3-shift operation. The system also enables filling of highly viscous products and complies with all current, even more stringent regulatory requirements introduced after the project began.

During the project, the team repeatedly faced changing challenges due to the current global market situation, such as short-term increases in raw material prices impacting the procurement of necessary components. Despite these circumstances and the extended supervision required due to longer delivery times, io was able to demonstrate clear economic advantages over comparable competitor projects in the end.

About Klosterfrau

Klosterfrau Berlin GmbH is a pharmaceutical company based in Berlin-Marienfelde. Under strict GMP guidelines (Good Manufacturing Practice), it produces medicated lozenges, liquid medicines, and sterile disposable syringes on 45,000 square meters. The product range includes, besides Klosterfrau Melissa Spirit, neo-angin®, Soledum®, nasic®, and Instillagel®. Additionally, Klosterfrau Berlin handles contract manufacturing for third-party companies. Today, around 300 dedicated employees work at Klosterfrau Berlin across various fields. The company is part of the Klosterfrau Group, which originated from the company founded in 1826 by the Klosterfrau Maria Clementine Martin in Cologne. The Klosterfrau Group now serves as the umbrella for companies in the fields of Consumer Healthcare, Medical, Contract Manufacturing, and Cosmetics. Central services such as finance, controlling, HR, IT, and many others are located at the headquarters in Cologne. Tradition and innovation shape the culture of the Klosterfrau Group and provide a valuable foundation for a successful future. With approximately 1,500 employees at 11 locations across Europe, the Klosterfrau Group is a driving force in the healthcare industry.